Method and apparatus for modularized inlet silencer baffles

ABSTRACT

A system includes a conduit having a fluid flow path and a silencer baffle disposed in a fluid conduit along the fluid flow path, where the silencer baffle has at least two of the plurality of baffle sections are coupled together via mating interlock structures.

BACKGROUND

The subject matter disclosed herein relates to systems and methods forsilencing noise within an air duct for a gas turbine engine.

Power generation equipment, such as a gas turbine engine, can use alarge supply of intake air to support the combustion process. Tomaintain suitable performance of the turbine, the intake air is filteredto remove unwanted dust, moisture, and other contaminants before the airis compressed in a compressor. The large volume of air that movesthrough the intake air housing and an air duct can generate significantnoise and cause vibration of the intake air housing and other equipment.Moreover, the blade passing frequency of the compressor and the inletbleed heating system may contribute to the noise and vibration. Incontext of turbine engines, it is generally undesirable to add to thevibration of the engine. As such, it is desirable to reduce noise andvibration caused by the intake air moving through the intake air housingand the air duct.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimedsubject matter are summarized below. These embodiments are not intendedto limit the scope of the claimed subject matter, but rather theseembodiments are intended only to provide a brief summary of possibleforms of the subject matter. Indeed, the subject matter may encompass avariety of forms that may be similar to or different from theembodiments set forth below.

In a first embodiment, a system includes a conduit having a fluid flowpath and a silencer baffle disposed in a fluid conduit along the fluidflow path, where the silencer baffle has at least two of the pluralityof baffle sections are coupled together via mating interlock structures.

In a second embodiment, a system includes a first baffle section of asilencer baffle configured to mount in a fluid conduit along a fluidflow path, where the first baffle section is coupled together with asecond baffle section of the silencer baffle via mating interlockstructures.

In a third embodiment, a system includes a first baffle section of asilencer baffle configured to mount in a fluid conduit along a fluidflow path, where the first baffle section is configured to coupledtogether with a second baffle section of the silencer baffle. The systemincludes a support rod configured to extend through a first support rodpassage in the first baffle section and a second support rod passage inthe second baffle section.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present subjectmatter will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic diagram of an embodiment of a power generationsystem with a silencer baffle having a plurality of modularized bafflesections disposed within an air duct of an inlet housing;

FIG. 2 is a cross-sectional view of an embodiment of the plurality ofbaffle sections of FIG. 1 taken along line 2-2, showing alignment of thebaffle sections and a plurality of silencer baffles;

FIG. 3 is a close-up perspective view of an embodiment of an exteriorsurface of a baffle section of the silencer baffle;

FIG. 4 is a close-up perspective view of an embodiment of an exteriorsurface of a trailing edge baffle section of the silencer baffle;

FIG. 5 is a perspective view of an embodiment of a single baffle shellof the plurality of baffle sections filled with a sound absorptionmaterial;

FIG. 6 is a cross-sectional view of an embodiment of the plurality ofbaffle sections of FIG. 2 taken along line 6-6 of FIG. 2, showingalignment of a plurality of rods disposed within the plurality of bafflesections via a plurality of rod support passages;

FIG. 7 is a cross-sectional view of an embodiment of a panel or sidewallhaving a plurality of mounting interface structures configured toreceive an end of a respective rod via a plurality of mountingreceptacles, wherein the panel is disposed along a top or a bottom sideof the inlet air housing of FIG. 1 taken along line 7-7;

FIG. 8 is a cross-sectional view of an embodiment of a panel or sidewallhaving a plurality of mounting interfaces configured to receive the endsof the rods via a plurality of mounting receptacles, wherein themounting interfaces have an open end and where the panel is disposedalong the top or the bottom side of the inlet air housing of FIG. 1taken along line 7-7;

FIG. 9 is a partial perspective view of an embodiment of a mountingreceptacle taken within line 9-9 of FIG. 6;

FIG. 10 is a close-up perspective view of an embodiment of the silencerbaffle, wherein the silencer baffle is configured to move radiallyand/or axially into the mounting interface structure;

FIG. 11 illustrates an embodiment of a partially assembled silencerbaffle of FIG. 1 illustrating an assembly process for a silencer baffle;

FIG. 12 illustrates an embodiment of a connector assembly taken withinline 9-9 of FIG. 6;

FIG. 13 illustrates another embodiment of a connector assembly takenwithin line 9-9 of FIG. 6;

FIG. 14 illustrates another embodiment of a connector assembly takenwithin line 9-9 of FIG. 6;

FIG. 15 illustrates a method of manufacturing the baffle sections inaccordance with the embodiments disclosed herein;

FIG. 16 illustrates a method of installing the silencer baffles inaccordance with the embodiments disclosed herein; and

FIG. 17 illustrates a method of removing the silencer baffles inaccordance with the embodiments disclosed herein.

DETAILED DESCRIPTION

One or more specific embodiments of the present subject matter will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

When introducing elements of various embodiments of the present subjectmatter, the articles “a,” “an,” “the,” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

Embodiments of the claimed subject matter include a power generationsystem including a gas turbine engine, wherein the system includes aconduit (e.g., an intake or exhaust housing and duct) for flowing afluid (e.g., air, recirculated exhaust gas, etc.) to a compressor. Oneor more silencer baffles is disposed in the housing or duct (e.g.,intake or exhaust). The silencer baffles include a plurality of bafflesections aligned substantially linearly with one another. The bafflesections are coupled together via a lockable coupling, such as a matinginterlock structures. The mating interlock structures may include afemale joint portion and a male joint portion that secure adjacentbaffle sections together when coupled. For example, the mating interlockstructures may include mating rail portions, mating dovetail joints,mating hook and slot joints, mating latches, or any combination thereof.Two or more baffle sections are assembled to form a silencer baffle. Thebaffle sections of the silencer baffle may form a plurality of rows andcolumns when assembled and installed into the inlet air housing and/orair duct. The baffle sections may be used within an intake section(e.g., intake section, exhaust gas recirculation, intake section, etc.),an exhaust system, or any other suitable area (e.g., areas with suitabletemperatures) of the power generation system.

The columns of the baffle sections are further stabilized by a roddisposed through a rod support passage disposed in the baffle section.The baffle sections are layered onto the rod one by one adjacent to eachother. The mating interlock structure (e.g., male joint portion) of eachbaffle section is coupled or inserted to an adjacent baffle section viaan adjacent mating interlock structure (e.g., female joint portion)after being layered onto the rod. The rod is then secured to the area ofthe power generation system where the silencer baffle is going to beused in (e.g., inlet air housing or inlet ducting). The rod is coupledto the area via its end portions. The end portions of the rods arecoupled to a panel having a prefabricated mounting interface. Themounting interface includes a plurality of recesses (e.g., mountingreceptacles) to receive the end portions of the rods. The ends of therods are coupled to the mounting receptacles via connector assemblies,as described in detail below.

The silencer baffle includes a leading edge baffle section, a trailingedge baffle section, and intermediate sections disposed between theleading and trailing baffle sections. The perimeter of the silencerbaffle gradually curves (e.g., tapers) from the leading baffle sectionto the trailing section, creating a more aerodynamic shape (e.g., anairfoil shaped baffle). In some embodiments, the perimeter of thesilencer baffle may include a blunt trailing edge and/or a leading edge.The baffle sections may have patterns on exterior surfaces of the bafflesections. The patterns may include recesses and/or protrusions (e.g.,dimples) and allow noise to be absorbed by acoustic materials (e.g.,sound absorption materials) disposed within the baffle shell.

Turning now to the drawings, FIG. 1 is a schematic diagram of anembodiment of a power generation system 10 with a silencer baffle 28including a plurality of baffle sections 36 disposed within an inlet airhousing 26 having an intake duct (e.g., air duct 27) that usesmodularized silencer baffle sections 36 disclosed herein. In thefollowing discussion, reference may be made to various directions,including an axial direction or axis 13, a radial direction or axis 15,and/or a circumferential direction or axis 17. The power generationsystem 10 includes a gas turbine engine 12 having a compressor 14 andone or more combustors 16 to receive and combust a mixture of compressedoxidant (e.g., air 24) and fuel 18, and one or more turbines 20 drivenby hot gases produced by combustion of the air-fuel mixture.

The hot combustion gases drive the turbine 20, which in turn drives thecompressor 14 and one or more other loads 22. For example, in theillustrated embodiment, the gas turbine engine 12 may be coupled to avariety of loads 22, such as an electrical generator. The remaining hotgases exit through an exhaust stack 30 and are vented to the atmosphere.The gas turbine engine 12 draws intake gas 24 (e.g., oxidant such asambient air) into the air compressor 14 through the air inlet housing 26and the air duct 27. Although the illustrated embodiment depicts air 24,the intake gas 24 may include air, oxygen, oxygen-enriched air,oxygen-reduced air, exhaust recirculation gas (EGR), or any combinationthereof. Nevertheless, the following discussion refers to air as anon-limiting example. As the intake air 24 enters the power generationfacility 10, the intake air 24 first passes through, the air inlethousing 26 (e.g., in the axial direction 13) that is coupled to the gasturbine engine 12. The air inlet housing 26 includes a sidewallextending about an intake air passage, wherein the sidewall includesopposite sidewall portions or panels, such as a top panel 82 and abottom panel 84. The silencer baffles 28 are secured to the top andbottom panels 82, 84 as described in detail below. Inside the inlet airhousing 26, an array of silencer baffles 28 is utilized as described indetail below. The silencer baffles 28 may also be utilized in a ventsystem 32, or other area of the gas turbine engine 12, where thetemperature of the gases is low enough to utilize the silencer baffles28 made of non-metallic materials (e.g., plastics, composites, etc.). Inother embodiments, the silencer baffles 28 may be made of metallicmaterials, or metallic/non-metallic composite materials. In one example,the vent system 32 may include a fan 34 to reduce the temperature of thegases being vented through the vent system 32 such that the silencerbaffles 28 can be used.

FIG. 2 is a cross-sectional view of an embodiment of the plurality ofbaffle sections 36 of FIG. 1 taken along line 2-2, showing alignment ofthe baffle sections in a plurality of silencer baffles 28. Though eachsilencer baffle 28 (e.g., rows of baffle sections 36) shows four bafflesections 36 aligned and interlocked with one another. Each of thesilencer baffles 28 may include any number of baffle sections 36 in eachrow 38. For example, the silencer baffles 28 may include 2, 3, 4, 5, 6,7, 8, or more baffle sections 36. The array of the silencer baffles 28includes a plurality of rows 38 and a plurality of columns 40 (see FIG.6) made up of modules (e.g., the baffle sections 36). In the illustratedembodiment, an equal number of rows 38 and columns 40 are utilized ineach silencer baffle 28. However, it will be appreciated that in someembodiments, each silencer baffle 28 may include more rows 38 thancolumns 40 or vice versa. In the following discussion, the columns 40may be referred to as panels 41 (e.g., vertically or radially stackedsegments). The embodiments disclosed herein may use any number of panels41. For example, there may be 2 to 50, 5 to 30, or 15 to 25 panels usedin the power generation system 10. The panels 41 are alignedsubstantially parallel to one another and separated by a space 43.

The baffle sections 36 are coupled together via a plurality of lockablecouplings, such as mating interlock structures 42. The mating interlockstructures 42 may include mating joint structures (e.g., a male jointportion 44 and a female joint portion 46). The male joint portion 44 isdisposed in the female joint portion 46 to increase rigidity of thecoupling. The mating interlock structures 42 may include a rail joint,dovetail joint 48, a butt joint, a tongue in groove assembly, or anyother suitable locking structure. For example, the joint portions 44 and46 may include male and female portions, dovetail joint portions, latchportions, hook and slot portions, or any combination thereof. In theillustrated embodiment, the joint portions 44 and 46 may include adiverging male joint portion 44 and a diverging female joint portion 46(e.g., diverging surfaces) that interlock with one another. The jointportions 44 and 46 may slidingly couple together in the radial direction15, and thus may be described as mating rail portions. The bafflesections 36 are aligned adjacent to one another. In the illustratedembodiment, the baffle sections 36 are arranged linearly in the axial 13and the radial directions 15 to form a grid like configuration ormatrix.

Each of the baffle sections 36 includes a rod support passage 50 (e.g.,rod receptacle) to receive a support rod 52 (see FIG. 6). The rodsupport passage 50 may be circular, rectangular, square, or any othersuitable geometry to receive the support rod 52. The support rods 52secure the columns 40 of the baffle sections 36 together, as explainedfurther with reference to FIG. 11. Each panel 41 may have a varyingnumber of support rods 52. For example, the panel 41 may have 2, 3, 4,5, 6, 7, 8 or more support rods 52. In some embodiments, not all of therod support passages 50 are used. For example, the panel 41 may haverods 52 disposed in every other rod support passage 50, every two rodsupport passages 50, and so forth.

The silencer baffle 28 includes a leading edge baffle section 54 havinga leading edge 55, a trailing edge section 56 having a trailing edge 57,and one or more intermediate baffle sections 58 disposed between theleading and trailing edge baffle sections 54, 56 in each row 38. Theintake air 24 flows through from a first side 60 of the inlet airhousing 26 to a second side 62. As the intake air 24 flows through theinlet air housing 26, the air flow is improved by the more aerodynamicshape of the silencer baffle 28. The baffle sections 36 may include acontoured exterior surface 64 between the leading edge section 54 andthe trailing edge section 56 of the silencer baffle, thereby forming anairfoil shaped perimeter 66 of the silencer baffle 28. For example, theleading edge section 54 may be wider than the trailing edge section 56and the intermediate sections 58. The baffle sections 36 may includevarious patterns 68 disposed on an exterior surface 70 of the bafflesections 36, as explained further with reference to FIGS. 3-4. Thepatterns 68 also may provide recesses or openings through which theinlet air 24 is blown through.

FIG. 3 is a close-up perspective view of an embodiment of the exteriorsurface 70 of one or more baffle sections 36 (e.g., leading edge bafflesection 54) of the silencer baffle 28. The pattern 68 disposed on theexterior surface 70 of the leading edge baffle section 54 includes aplurality of recesses or openings 72. The openings 72 may coverapproximately 20 to 60%, 25 to 50%, 30 to 40%, and all percentagestherebetween of the exterior surface 70 of one or more baffle sections36. The openings 72 enable the inlet air 24 to be exposed to theopenings and allows noise to be absorbed by acoustic materials 74 (e.g.,sound absorption materials) disposed within an interior 76 (see FIG. 5)of the one or more baffle sections 36. The openings 72 may be disposedon any or all of the baffle sections 36, such as the leading edge bafflesection 54, the trailing edge baffle section 56, and/or the intermediatebaffle sections 58. In the illustrated embodiment, the opening 72 mayhave a substantially square or rectangular shape with one or morerounded or chamfered edges 78. In other embodiments, the openings 72 mayhave other shapes including ovals, circles, triangles, hexagons, orcombination thereof. The adjacent openings 72 may by a space or a rib79, which may be flush or protruding relative to the exterior surface 70and/or the openings 72. In certain embodiments, the ratio of the widthof the opening 72 to the rib 79 may be approximately 10:1 to 1:1, 8:1 to2:1, or 3:1 to 1.5:1, or any ratios therebetween.

FIG. 4 is a close-up perspective view of an embodiment of the exteriorsurface 70 of the one or more baffle sections 36 of the silencer baffle28. The exterior surface 70 may include one or more patterns 68configured to increase turbulence and/or to reduce flow separation ofthe inlet air 24 relative to the exterior surface, such as along thetrailing edge baffle sections 56. In the illustrated embodiment, thepattern 68 includes a dimple pattern 74. In certain embodiments, thedimple pattern 74 creates turbulent flow of the air at least around thetrailing edge section 56, thereby delaying flow separation near thetrailing edge section 56. The dimple pattern 74 may include a pluralityof polygonal shapes (e.g., hexagonal shapes, octagonal shapes, etc.),circular shapes, or any other suitable geometry, such that the dimplecreates turbulent flow.

FIG. 5 is a perspective view of an embodiment of a single baffle section36 of the plurality of baffle sections 36 having a baffle shell 76filled with a sound absorption material 78. As shown, the baffle shell76 includes an outer shell portion 75, an inner structural support 77,and the rod support passage 50 (e.g., along support 77) to receive thesupport rod 52. The baffle shell 76 may be formed by injection molding,transfer molding, or any other suitable process. The baffle shell 76 maybe constructed of suitable materials including plastics, such asacrylonitrile butadiene styrene, polypropylene, polyethylene, PVC, CPVC,or other suitable thermoplastic polymers. In some embodiments, thebaffle shell 76 may be formed of composite materials (e.g., areinforcement material distributed throughout a matrix material). Thesound absorption material 78 may include mineral woods, basalt wool,fiberglass, melamine foam, polyurethane foam, or other suitablematerials. As explained above, the baffle sections 36 are arranged incolumns 40 (e.g., stacked one over another in radial direction 15) andcoupled together in rows 38 (e.g., interlocked in axial direction 13)via the mating interlock structures 42 (e.g., the male joint portion 44,the female joint portion 46). The sound absorption material 78 may becut to a suitable shape and size and inserted into the baffle shell 76to function as a noise attenuation component. In other embodiments, thesound absorption material 78 may be injected into the baffle shell 76.The baffle shells 76 may be formed individually and slid onto the rod 52to form an integral silencer baffle 28. The sound absorption material 78may be placed into the baffle shell 76 before or after being threaded(e.g., assembled) on the rod 52.

FIG. 6 is a cross-sectional view of an embodiment of the plurality ofbaffle sections 36 of FIG. 2 taken along line 6-6, showing alignment ofa plurality of rods 52 disposed within the plurality of baffle sections36. The dashed lines 85 represent the overlap and interlocking of themale joint portion 44 with the female joint portion 46 when the matinginterlock structure 42 is coupled together (e.g., slidingly coupledtogether) in the radial direction 15. The rods 52 may constrain thepanels 80, 82, 84 and function as a load bearing element to reduce theload on the panels 80, 82, 84. As discussed above, the rods 52 may becircular, square, rectangular, or any other suitable geometry. In theillustrated embodiment, the rods 52 have a diameter of approximately3.81 centimeters (1.5 inches), though the diameter may vary. Thediameter of the rods 52 may vary to fit the opening or rod supportpassages 50. As discussed above, the rods 52 are disposed through rodsupport passages 50 to stabilize the columns 40 (e.g., the bafflesections 36). The rods 52 couple to adjacent panels 80 (e.g., a toppanel 82, a bottom panel 84) of the inlet air housing 26 by end portions94 of the rod 52. Each of the rods 52 is secured to the adjacent panels80 via a plurality of connector assemblies 86. Various embodiments ofthe connector assemblies 86 may be further understood with reference toFIGS. 9 and 12-14.

FIGS. 7-8 illustrate cross-sectional views of embodiments of the wallportion of panel 80 of the housing 26 and/or duct 27 of FIG. 1 takenalong line 7-7, illustrating a plurality of mounting interfaces 88disposed in the panels 80. It may be appreciated that the mountinginterfaces 88 may not be utilized in some embodiments. The mountinginterfaces 88 may include various openings (e.g., receptacles) toreceive a portion of the rods 52 (e.g., end portions 94). The mountinginterface 88 may be flat (e.g., flush with the panel 80), recessed intothe panel 80, and/or or protruding outward from the panel 80. In someembodiments, the mounting interface 88 may include an outer border orrim 89 in the panel 80 or which may be recessed or protruding from thepanel 80 to define a perimeter of the mounting interface 88. FIG. 7 is across-sectional view of an embodiment of a panel 80 comprising aplurality of mounting interfaces 88 configured to receive the ends 94 ofthe rods 52 via a plurality of mounting receptacles 90, wherein thepanel 80 is disposed along the top 82 or the bottom 84 side of the inletair housing 26 of FIG. 1 taken along line 7-7. During assembly, eachcolumn 40 of the baffle sections 36 is assembled by radially stackingthe baffle sections 36 over one another along a support rod 52 disposedin the receptacle 90 in one of the panels 80 (e.g., a bottom panel 84).Subsequently, each additional column 40 of baffle sections 36 isassembled by sliding each successive baffle section 36 along the matinginterlock structure 42 between adjacent columns 40 with or withoutsimultaneously sliding the successive baffle sections 36 along anadditional support rod 52. After the desired number of columns 40 ofbaffle sections are assembled in the housing 26, the end portion 94 ofeach rod 52 is inserted (see FIG. 9) into the mounting receptacle 90 inan opposite panel 80 (e.g., a top panel 82). The end portion 94 of eachrod 52 is then locked into the mounting receptacle 90 via the connectorassembly 86. The mounting interfaces 88 may be prefabricated into bothpanels 80 (e.g., the top panel 82, the bottom panel 84) via metalstamping, casting, machining, and/or welding a separate structure ontothe panels 80.

FIG. 8 is a cross-sectional view of an embodiment of a panel 80comprising mounting a plurality of mounting interfaces 88 configured toreceive the ends 94 of the rods 52 via a plurality of mountingreceptacles 90, wherein the mounting interfaces 88 have an open end 92and wherein the panel 80 is disposed along a top 82 or bottom 84 side ofthe inlet air housing 26 of FIG. 1 taken along line 7-7. In theillustrated embodiment, each mounting interface 88 has an outer borderor rim 89 with a constant width 91 from the open end to a closed end 93.For example, the rim 89 may define a rail mount structure, which blocksmovement of the silencer baffles 28 in the crosswise direction 19. Inthe illustrated embodiment, the mounting interface 88 includes the openend 92 so that the baffle sections 36 (e.g., individual baffle sections36, preassembled rows 38, and/or columns 40 of baffle sections 36) canbe slid axially 13 into the mounting interface 88 one-by-one in amodular fashion (e.g., assembling by layering the baffle sections 36).The columns 40 of the baffle sections 36 (and each entire silencerbaffle 28) can then be further stabilized by inserting one or more rods52 through one or more rod support passages 50 and then into themounting receptacles 90, as shown more clearly in FIG. 9.

FIG. 9 is a close-up perspective view of an embodiment of the mountinginterface 88 taken within line 9-9 of FIG. 6, illustrating a bafflesection 36 of the silencer baffle 28 being installed into a space 95between portions of the rim 89. For example, the illustrated mountinginterface 94 may be disposed on one or both of the opposite panels 80(e.g., top panel 82 and/or bottom panel 84) of the housing 26. Incertain embodiments, the mounting interface 94 may be the same ordifferent panels 82, 84. The mounting receptacle 90 receives the endportion 94 of the rod 52. In some embodiments, the rods 52 are thensecured (e.g., locked) into place by the connector assemblies 86 (seeFIGS. 12-14) at one or both of the opposite panels 80 (e.g., panels 82,84). When the silencer baffle 28 is to be replaced, the rod 52 isremoved near the end portion 94 to remove the column 40 of bafflesections 36. Some of the connector assemblies 86 may result indetachable couplings, while other configurations result insemi-permanent couplings. In the case of a detachable coupling, the rod52 may be removed by uncoupling the connector assembly 86. In the caseof a semi-permanent connection, the rod 52 may be removed by cutting aweld with a torch or other suitable apparatus. In certain embodiments,at least one of the opposite panels 80 (e.g., the top panel 82) may beremovable to enable top installation and removal through an accessopening.

FIG. 10 is a close-up perspective view of an embodiment of the silencerbaffle 28, wherein the silencer baffle 28 is translated into themounting interface 88 (e.g., radially into the closed airfoil shapedinterface or axially into an open-ended rail interface). As describedabove, the silencer baffle 28 may be comprised of any number of bafflesections 36. The silencer baffle 28 may be assembled by assembling thecolumns 40. Each column 40 includes a plurality of the baffle sections36. The baffle sections 36 are assembled along the rod 52 by sliding thebaffle sections 36 one by one onto the rod 52 through the rod supportpassage 50. The baffle sections 36 are coupled (e.g., snapped together,fitted together) by the female and male joint portions 44, 46. After thedesired number of columns 40 of baffle sections 36 are formed, the rod52 is inserted into the mounting receptacles 90 of the mountinginterface 88, as described above.

In another embodiment, the mounting interface 88 includes the open end92 so that the baffle sections 36 can be slid axially into the mountinginterface 88 one-by-one or row by row in a modular fashion. In otherwords, the baffle sections 36 may be positioned (e.g., aligned) in themounting interface 88. The baffle sections 36 are aligned so that therod support passages 50 are substantially aligned with one another. Thebaffle sections 36 are coupled (e.g., snapped together, fitted together)by the female and male joint portions 44, 46. The columns 40 of thebaffle sections 36 can then be further stabilized by inserting the rod52 through the rod support passages 50. The end portions 94 of the rods52 may then be secured to the mounting receptacles 90, as describedabove.

FIG. 11 illustrates an embodiment of a partially assembled silencerbaffle 28 of FIG. 1. The baffle sections 36 are layered in the radialdirection 15 onto each of the rods 52 one-by-one. In the illustratedembodiment, the columns 40 a, 40 b are fully assembled. The column 40 dis partially assembled with only one baffle section 36 on the rod 52.The dashed lines 85 indicate overlap of adjacent baffle sections 36 viathe mating interlock structures 42 (e.g., male joint portion 44 and thefemale joint portion 46). Locking the mating interlock structures 42further stabilizes the baffle sections 36 into the aligned columns 40and rows 38. Locking the mating interlock structures 42 may includeinserting the male joint portion 44 into the female joint portion 46,snapping the joint portions 44, 46 together, fitting the joint portions44, 46 together, or any other suitable manner of coupling. The column 40c illustrates a column partially assembled column 40 of the bafflesections 36, with a final baffle section 36 being installed at the topof the column 40 c. As shown, each rod 52 is coupled to the bottom panel84. As described above, the bottom panel 84 is prefabricated with matinginterfaces 88 and mating receptacles 90. Each rod 52 may be secured tothe mating receptacle 90 prior to the baffle sections 36 being slid ontothe rod 52. The baffle sections 36 are then slid onto the rod 52 via therod support passages 50 until the desired number of baffle sections 36are stacked onto the rod 52 to complete each column 40. The process isrepeated for each column 40 of the baffle sections 36, while eachadjacent pair of columns 40 of baffle sections 36 may alsosimultaneously interlock with one another with the interlock structures42. As illustrated, the interlock structures 42 are configured to engageone another in the radial direction 15 simultaneous with lowering of thebaffle sections 36 onto the rod 52 in the radial direction 52. After allof the baffle sections 36 are assembled to define the desired number ofsilencer baffles 28, the top panel 80, 82 may be installed over thesilencer baffle 28 to capture the silencer baffle 28 between oppositepanels 80. The top panel 80, 82 also secures the rods 52 via insertionof the rods 52 into receptacles 90 in the top panel 80, 82. In someembodiments, the baffle sections 36 may be arranged (e.g., layered)adjacent to each other, and the rod 52 may be slid into the bafflesections 36 by sliding the rod 52 through the aligned rod supportpassages 50. In other embodiments, the silencer baffle 28 may beassembled by assembling the baffle sections 36 in the axial direction,as described above with reference to FIG. 10. In this embodiment, thebaffle sections 36 may be fully layered (e.g., assembled) in the axialdirection. The rod 52 may then be disposed through the adjacent bafflesections 36 by inserting the rod 52 through the rod support passages 50.

FIGS. 12-14 illustrate various embodiments of the connector assemblies86 utilized to couple the end portion 94 of the rod 52 to the mountingreceptacles 90. The connector assemblies 86 may be semi-permanentcouplings, such as welding, brazing, fusing, or a combination thereof.The connector assemblies 86 may be removable couplings, such asfasteners (e.g., threaded receptacles, bolts, nuts, etc.), clamps, orany combination thereof. The connector assemblies 86 may also serve toblock the rod 52 from inadvertently loosening over time due tovibration.

FIG. 12 illustrates an embodiment of the connector assembly 86, whereinthe connector assembly 86 couples the rod 52 to the mounting receptacle90 in the mounting interface 88. In the illustrated embodiment, the rod52 is inserted radially 15 into the mounting receptacle 90, while thesilencer baffle 28 is disposed within the rim 89. The mounting interface88 is coupled to an inner wall 96 of the panel 80 (e.g., top panel 82).The inner wall 96 of the panel 80 is thermally isolated from an outerwall 98 of the panel 80 (e.g., top panel 82) by a layer of insulation102. The layer of insulation 102 may vary in thickness. The insulation102 may be the same insulation material that is utilized inside thebaffle shells 76, or it may be different. The mounting interface 88 maybe removably or fixedly coupled to the panel 80 via removable fasteners(e.g., threaded fasteners, clamps, male/female joints, etc.) or fixedjoints (e.g., welds, brazed joints, etc.)

FIG. 13 illustrates another embodiment of the connector assembly 86,wherein the connector assembly 86 couples the rod 52 to the mountingreceptacle 90. The inner wall 96 of the panel 80 is separated from theouter wall 98 of the receiving structure by a layer of insulation 102.The connector assembly 86 includes a perforated panel or a washer 104.The washer 104 may support the load associated with the rod 52 andbaffle sections 36 within the mounting interface 88. The rod 52 iscontained by at least one sleeve 106 that couple to the washer 104. Thesleeve 106 reduces movement of the rod 52 within the mounting interface88. In the illustrated embodiment, the end portion 94 of the rod 52, thewasher 104, and the sleeve 106 are contained within the panel 80 betweenthe inner wall 96 and the outer wall 98 (e.g., recessed into the panel80 within the insulation 102). When the rod 52 and silencer baffle 28(e.g., assembled baffle sections 36) are removed from the inlet airhousing 26, the rod 52 is cut adjacent the end portion 94 and the washer104, the end portion 94, and the sleeves 106 remain inside the innerwall 96 and the outer wall 98 of the mounting interface 88.

FIG. 14 illustrates another embodiment of the connector assembly 86,wherein the connector assembly 86 couples the rod 52 to the mountingreceptacle 90. The inner wall 96 of the panel 80 is separated from theouter wall 98 of the panel 80 by a layer of insulation 102. A pair ofremovable fasteners, such as a pair of bolts 112, is inserted throughthe inner wall 96. The pair of bolts 112 may be disposed through aportion of the mounting receptacle 90. The mounting receptacle 90 isdisposed outside the inner wall 96 and may include a rod guide 110. Therod guide 110 may be used to align the rod 52 within the mountingreceptacle 90. In the illustrated embodiment, the connector assembly 86may include the washer 104 to support the load of the rod 52.

FIG. 15 illustrates a method 150 of manufacturing the baffle sections 36in accordance with the embodiments disclosed herein. The method 150includes forming (block 152) the baffle shell 76 with mating interlockfeatures 42 and one or more rod support passages 50. As described above,the baffle shell 76 may be manufactured via injection molding, transfermolding, or another suitable method. The method 150 includes filling(block 154) an interior portion of the baffle shell 76 with the silencermaterial 80. In some embodiments, the interior portion of the baffleshell 76 may be injected with the silencer material 80, or the silencermaterial 80 may be cut and inserted into the baffle shell 76. Thesilencer material may include various foams, such melamine foam,polyurethane foam, or other suitable foam materials. The method 150includes forming (block 156) a pattern 68 on the exterior surface 70 ofthe baffle shell 76. The pattern 68 may include recesses, openings 72,protrusions or dimples 74, or a combination thereof. It may beappreciated in some embodiments, some of the steps may be performed in asingle step. For example, the method 150 may include includes forming(block 152) the baffle shell 76 with mating interlock features 42 andone or more rod support passages 50 forming (block 156) the pattern 68on the exterior surface 70 of the baffle shell 76 at once.

FIG. 16 illustrates a method 200 of installing the silencer baffles 28in accordance with the embodiments disclosed herein. The method 200includes installing (block 202) the silencer baffles 36 in a column 40along the rod 52. The method 200 may include inspecting, servicing,repairing, and/or replacing one or more of the baffle sections 36 duringinstallation. The silencer baffles 36 include rod support passage 50, sothat the silencer baffles 36 can slide radially 15 onto the rod 52.Adjacent columns 40 of the baffle sections 36 are coupled together(e.g., snapped together, fitted together) by the female and male jointportions 44, 46. The method 200 includes aligning (block 204) theassembled silencer baffle 28 (e.g., the rod 52 with silencer baffles 36)with the mounting receptacles 90 that are prefabricated on the panels 80(e.g., top panel 82, bottom panel 84) of inlet air housing 26. Themethod 200 includes repeating (block 206) the steps of installing thesilencer baffles 36 and aligning the assembled silencer baffle 28 untilthe desired number of rows 38 and columns 40 is reached.

FIG. 17 illustrates a method 250 of removing the silencer baffles 28 inaccordance with the embodiments disclosed herein. The method 250 mayinclude inspecting, servicing, repairing, and/or replacing one or moreof the baffle sections 36 during removal. The method 250 includeuncoupling (block 252) the rods 52 at end portions 94 from the panels80. Uncoupling the rods 52 includes uncoupling the connector assemblies86. As described above for detachable couplings, each rod 52 may beremoved by uncoupling the connector assembly 86. For example, the rods52 may be removed by unthreading threaded fasteners, removing the toppanel 80, 82, removing clamps, or any combination thereof. In the caseof a semi-permanent connection, the rod 52 may be removed by cutting aweld with a torch, a blade, or an abrasive tool. The method 250 includesrepeating (block 254) uncoupling the rods 52 until number of rows ofbaffles to be disassembled is reached. The method 250 includesinstalling (block 256) a newly assembled (e.g., replacement) rod 52 inthe mounting receptacles 90 to secure silencer baffles 28 to panels 80of the air inlet housing (e.g., duct). In some embodiments, the step ofinstalling (block 256) a replacement rod 52 may be optionally omitted.

Technical effects of the subject matter include forming silencer baffles28 by assembling a plurality of baffle sections 36 within the air intakeconduit of a gas turbine engine 12. Each silencer baffle 28 includes aleading edge baffle section 54, a trailing edge baffle section 56, andone or more intermediate sections 60 disposed between the leading andtrailing baffle sections 54, 56. The baffle sections 36 may havepatterns 68 on exterior surfaces of the baffle sections 36. The patterns68 (e.g., openings) serve to allows noise to be absorbed by acousticmaterials 74 (e.g., sound absorption materials) disposed within thebaffle shell 76. The baffle sections 36 are assembled in rows 38 andcolumns 40 to form silencer baffles 28. Each baffle section 36 include amale joint portion 44 and/or a female joint portion 46 that couples to acorresponding joint portion 44, 46 on an adjacent baffle section 36.Each of the baffle sections may also include a rod support passage 50configured to receive a rod 52. The rod 52 further stabilizes the maleand female joint portions 44, 46. The rods 52 with the baffle sections36 are installed in the inlet air housing 26 or other suitable locationof the power generation system 10. In accordance with the presentdisclosure, the end portions 94 of the rod 52 are coupled to a mountinginterface 88 via mounting receptacles 90. The rods 52 are coupled to themounting receptacles 90 via the connector assemblies 86. The rods 52 maybe replaced to maintain or replace the baffle sections 36 when thebaffle sections 36 are to be maintained, repaired, replaced, accessed,or otherwise inspected.

This written description uses examples to disclose the claimed subjectmatter, including the best mode, and also to enable any person skilledin the art to practice the subject matter, including making and usingany devices or systems and performing any incorporated methods. Thepatentable scope of the subject matter is defined by the claims, and mayinclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims.

1. A system, comprising: a conduit having a fluid flow path; and asilencer baffle disposed in a fluid conduit along the fluid flow path,wherein the silencer baffle has at least two of the plurality of bafflesections are coupled together via mating interlock structures.
 2. Thesystem of claim 1, comprising a machine coupled to the conduit.
 3. Thesystem of claim 2, wherein the machine comprises a turbine engine. 4.The system of claim 1, wherein the plurality of baffle sections of thesilencer baffle comprises a leading edge section and a trailing edgesection.
 5. The system of claim 4, wherein the plurality of bafflesections of the silencer baffle comprises one or more intermediatesections disposed between the leading and trailing edge sections.
 6. Thesystem of claim 1, wherein the plurality of baffle sections of thesilencer baffle comprises a contoured exterior surface between a leadingedge and a trailing edge of the silencer baffle.
 7. The system of claim6, wherein the contoured exterior surface defines an airfoil shapedperimeter of the silencer baffle.
 8. The system of claim 1, wherein theplurality of baffle sections of the silencer baffle comprises aplurality of rows and a plurality of columns.
 9. The system of claim 1,wherein the mating interlock structures comprise mating rail structures.10. The system of claim 9, wherein the mating rail structures comprise adovetail joint having a male dovetail joint portion disposed in a femaledovetail joint portion.
 11. The system of claim 1, wherein each of themating interlock structures comprise a male joint portion disposed in afemale joint portion.
 12. The system of claim 1, comprising one or moresupport rods extending through the plurality of baffle sections of thesilencer baffle.
 13. The system of claim 12, wherein each of the one ormore support rods extends through a column of sections of the silencerbaffle.
 14. The system of claim 1, wherein each of the plurality ofbaffle sections of the silencer baffle comprises a sound absorptionmaterial disposed in a shell.
 15. The system of claim 14, wherein eachof the plurality of baffle sections of the silencer baffle comprises arod support passage configured to receive a support rod.
 16. The systemof claim 1, wherein the silencer baffle has an exterior surface having apattern of recesses, openings, or a combination thereof.
 17. The systemof claim 16, wherein the pattern comprises hex shapes, octagonal shapes,circular shapes, or any combination thereof.
 18. The system of claim 1,comprising a plurality of silencer baffles disposed in the fluid conduitalong the fluid flow path, wherein each of the plurality of silencerbaffles has the plurality of baffle sections coupled together via themating interlock structures.
 19. A system, comprising: a first bafflesection of a silencer baffle configured to mount in a fluid conduitalong a fluid flow path, wherein the first baffle section is configuredto coupled together with a second baffle section of the silencer bafflevia mating interlock structures.
 20. A system, comprising: a firstbaffle section of a silencer baffle configured to mount in a fluidconduit along a fluid flow path, wherein the first baffle section isconfigured to coupled together with a second baffle section of thesilencer baffle; and a support rod configured to extend through a firstsupport rod passage in the first baffle section and a second support rodpassage in the second baffle section.